Filling process of differential-pressure cast for thin-wall castings of aluminum alloy is simulated with the hydraulic simulation method. The effects on filling fluid pattern was taken by the figure and amount of the ingate and the wall width of castings are researched. It is shown that the wall width of castings has obvious effect on critical pressure increase rate and critical filling rate, the thinner the wall width of castings is, the bigger the critical pressure increase rate and critical filling rate are; but the figure and the amount of the ingate has no obvious effect on the stationarety of filling. On the basis mentioned above, it is carried out that numeric simulation of filling process of differential-pressure cast and the process design of defferential -pressure cast to some large-scale thin-wall cabin-shape parts, and the result showes that are the smooth and stepwise filling,and the project of differential pressure cast is instituted by the process parameters, which is provide by the hydraulic simulation method. It provides the reference for the produce of this kind of castings.